Super hard alloy baseplate outer circumference cutting blade and manufacturing method thereof

Abstract

The disclosed cemented carbide base outer blade cutting wheel comprises a base in the form of an annular thin disc of cemented carbide, and a blade section on the outer periphery of the base. The blade section contains: diamond and/or CBN abrasive grains pre-coated with a magnetic material; a metal or alloy bond formed by electroplating or electroless plating for bonding abrasive grains together and to the base; and a metal or alloy binder having a melting point of up to 350° C. infiltrated between abrasive grains and between abrasive grains and the base. The method for manufacturing said outer blade cutting wheel is also disclosed.

The invention claimed is: 
     
       1. An outer blade cutting wheel comprising a base in the form of an annular thin disc of cemented carbide having a Young's modulus of 450 to 700 GPa, having an outer diameter of 80 to 200 mm defining an outer periphery, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm, and a blade section on the outer periphery of the base,
 said blade section comprising 
 diamond and/or CBN abrasive grains pre-coated with a magnetic material, 
 a first metal or alloy formed by electroplating or electroless plating, the first metal or alloy covering and bonding the pre-coated abrasive grains together and to the base, the pre-coated abrasive grains and the first metal or alloy constituting a porous bonded structure, and 
 a second metal or alloy having a melting point of up to 350° C. infiltrated and filling pores of the porous bonded structure and between abrasive grains and the base. 
 
     
     
       2. The cutting wheel of claim wherein the second metal is Sn and/or Pb. 
     
     
       3. The cutting wheel of  claim 1 , wherein the second metal or alloy has a Poisson's ratio between 0.3 and 0.48. 
     
     
       4. The cutting wheel of  claim 1 , wherein said base has a saturation magnetization of at least 40 kA/m (0.05 T). 
     
     
       5. The cutting wheel of  claim 1 , wherein said abrasive grains have an average grain size of 10 to 300 μm. 
     
     
       6. The cutting wheel of  claim 1 , wherein said abrasive grains have a mass magnetic susceptibility χg of at least 0.2. 
     
     
       7. The cutting wheel of  claim 1 , wherein the second alloy is at least one alloy selected from the group consisting of Sn—Ag—Cu, Sn—Ag, Sn—Cu, Sn—Zn, and Sn—Pb alloys. 
     
     
       8. A method for manufacturing an outer blade cutting wheel of  claim 1 , comprising the steps of:
 providing a base in the form of an annular thin disc of cemented carbide having a Young's modulus of 450 to 700 GPa, having an outer diameter of 80 to 200 mm defining an outer periphery, an inner diameter of 30 to 80 mm, and a thickness of 0.1 to 1.0 mm, 
 providing diamond and/or CBN abrasive grains pre-coated with a magnetic material, 
 placing a permanent magnet near the outer periphery of the base so that the magnetic field produced by the permanent magnet may act to magnetically attract and hold the coated abrasive grains close to the outer periphery of the base, 
 electroplating or electroless plating a first metal or alloy on the base outer periphery and the coated abrasive grains being magnetically attracted and held, for bonding the abrasive grains together and to the base to fixedly secure the abrasive grains to the base outer periphery to form a blade section with a porous structure constituted by the pre-coated abrasive grains and the first metal or alloy, and 
 letting a second metal or alloy having a melting point of up to 350° C. infiltrate into pores of the porous structure. 
 
     
     
       9. The method of  claim 8  wherein the second metal is Sn and/or Pb. 
     
     
       10. The method of  claim 8  wherein the second metal or alloy has a Poisson's ratio between 0.3 and 0.48. 
     
     
       11. The method of  claim 8 , wherein said base has a saturation magnetization of at least 40 kA/m (0.05 T). 
     
     
       12. The method of  claim 8 , wherein said abrasive grains have an average grain size of 10 to 300 μm. 
     
     
       13. The method of  claim 8 , wherein said abrasive grains have a mass magnetic susceptibility χg of at least 0.2. 
     
     
       14. The method of  claim 8 , wherein the permanent magnet produces a magnetic field of at least 8 kA/m within a space extending a distance of 10 mm or less from the base outer periphery. 
     
     
       15. The method of  claim 8 , wherein the second alloy is at least one alloy selected from the group consisting of Sn—Ag—Cu, Sn—Ag, Sn—Cu, Sn—Zn, and Sn—Pb alloys.